I noticed a few days ago that there was a draft coming from the passenger side of the cabin. Outside air temp that day was about -35c, so it wasn't hard to detect! I bumped up the passenger temp to 'HI' - no difference. Turned it all the way down to 'LO' and heard 4-5 nasty hard, clicking sounds, followed by the sound of something (plastic?) rattling around deep in the ducting.
Jeep just had it's second birthday, but is at ~75k kms, so outside of warranty. I also own a 2001 GC with a failed blend door, and this symptom is exactly the same. Someone please tell me that Chrysler has addressed this issue sometime in the past 11 years, and that my diagnosis is wrong.
Picked the Jeep up from dealer a few hours ago. Failed actuator motor and broken gear. Total parts = $65, labour ~$300. Dealer is solid - they're good-willing it 50/50 with me. I called Chrysler and the told me to suck it. Big surprise there.